Removal of damper rod bolts

[muzikill]

Heres how i did it...

Tools used. Cut hex key as required...


Front wheel axle bolt used to hold it in one place just jam it against your body when it turns.



Oil that came out..

Looking towards the front of the bike, Left fork that had the leak came out dark brown, right fork -the oil came out green.

Sorted...All cleaned up and ready to fill with new oil and refits .... well maybe....




The old oil seal is on the right, it's approx 11 m deep and probably around 1mm more in diameter. The supposed oem one is not deep enough for the retainer spring to fit right and it just 'plops' into the fork same goes for the 'new' dust seal. K3 sv650s different parts from the rest strikes again. These were advertised as 00-04 seals but are not. I checked with suzuki in cupar and the parts that they thought were right were the same size as the smaller ones .... damn... on order and have to wait!

part no's for the old ones that came off. read from the inside edge.

Dust seal - (NGK?) NOK 41-80 BR3420F 18
Oil seal - (NGK) NOK 88-4 41-80 BR20031

The smaller ones cost me around 15 quid. As soon as i get the right size someone can have them for a tenner delivered. Im pretty sure they will be ok for earlier models. the reason they are wrong will be the K3 first pointy curse.

EDIT: looking around ebay it seems that these are for curvy's. The seller i bought them from advertised them as 00-04's i thought they were right as the k3 uses some stuff from the curvy before the k4 changed everything again!

Try polishing out these scratches on the tubes before you refit them otherwise you may still have a leak
[It may be a reflection of the light I am looking at]


Glad the simple suggestion worked for you

Originally Posted by squirrel_hunter

But would this work on a fork where the damper rod bolt just spins the damper rod and internals?

Should do, generaly the buzz gun should spin the bolt fast enough that it loosen's before the internals get a change to spin. Did it when me and my mate changed the springs on his car, with a ratchet on th nut the rod just span, got the buzz gun on it and it was off in seconds.

[mikerj]

Originally Posted by squirrel_hunter

But if the bolt spins the rod even under compression how will an impact gun help?

Because an impact gun doesn't apply a continuous force, so even if the damper rod rotates the individual impacts will still apply a considerable amount of force to the bolt because of the inertia of the damper rod. This is why they are very effective for this job.

[MJC-DEV]

Should add that mikerj fitted my cartridge emulators yesterday and the damper rods were un-done in about 2 seconds each using the air impact gun (springs still fitted of course).

Nobody is denying the benefits of air tools but not everybody has them at their disposal. A properly equipped workshop makes most jobs much easier but for normal home maintenance does it justify the expense of fitting out a normal household garage?
I would love a decent compressor,a set of in line vices,,ramp and a pit,plus of course a rising motorbike ramp,even an overhead lifter is a necessity but who has all that in an normal garage.

[squirrel_hunter]

Originally Posted by Holdup

Should do, generaly the buzz gun should spin the bolt fast enough that it loosen's before the internals get a change to spin. Did it when me and my mate changed the springs on his car, with a ratchet on th nut the rod just span, got the buzz gun on it and it was off in seconds.

Originally Posted by mikerj

Because an impact gun doesn't apply a continuous force, so even if the damper rod rotates the individual impacts will still apply a considerable amount of force to the bolt because of the inertia of the damper rod. This is why they are very effective for this job.

Cheers guy, just wondering. I've not needed to try air tools out on forks yet but will keep this in mind.

Originally Posted by Dicky Ticker

Nobody is denying the benefits of air tools but not everybody has them at their disposal. A properly equipped workshop makes most jobs much easier but for normal home maintenance does it justify the expense of fitting out a normal household garage?
I would love a decent compressor,a set of in line vices,,ramp and a pit,plus of course a rising motorbike ramp,even an overhead lifter is a necessity but who has all that in an normal garage.

I agree with you not everybody has the fully equipped workshop and thats why the broom handle has worked for me in the past the the axle approach has worked here.

[muzikill]

Should i replace the damper bolts? - ive got stainless steel bolts the same size but dunno if this means i'd be replacing them will a lesser strength.

[yorkie_chris]

Originally Posted by squirrel_hunter

But would this work on a fork where the damper rod bolt just spins the damper rod and internals?

Yes

[yorkie_chris]

Originally Posted by muzikill

Should i replace the damper bolts? - ive got stainless steel bolts the same size but dunno if this means i'd be replacing them will a lesser strength.

No